Semiconductor Structure with Stress-Reducing Buffer Structure

ABSTRACT

A semiconductor structure comprising a buffer structure and a set of semiconductor layers formed adjacent to a first side of the buffer structure is provided. The buffer structure can have an effective lattice constant and a thickness such that an overall stress in the set of semiconductor layers at room temperature is compressive and is in a range between approximately 0.1 GPa and 2.0 GPa. The buffer structure can be grown using a set of growth parameters selected to achieve the target effective lattice constant a, control stresses present during growth of the buffer structure, and/or control stresses present after the semiconductor structure has cooled.

REFERENCE TO RELATED APPLICATIONS

The current application claims the benefit of U.S. ProvisionalApplication No. 61/943,365, which was filed on 22 Feb. 2014, and whichis hereby incorporated by reference.

TECHNICAL FIELD

The disclosure relates generally to semiconductor structures, and moreparticularly, to a semiconductor structure having an improved bufferstructure.

BACKGROUND ART

Group III nitride semiconductors are widely used for fabricatingefficient blue and ultraviolet light emitting devices (e.g., diodes,lasers, etc.), ultraviolet detectors, and field effect transistors. Dueto a wide band-gap, these materials are a leading choice for fabricatingdeep ultraviolet light emitting diodes (DUV LEDs). In recent years,significant advances have been made in improving the efficiency of DUVLEDs. However, overall efficiencies of these devices remain low. Forfabrication of DUV LEDs, achieving a high quality aluminum nitride (AlN)buffer layer as an underlying layer can be important for the subsequentgrowth of any Al-rich group III nitride semiconductor layers. However,growth of an AlN layer with high crystal quality on substrates formed ofsapphire, silicon carbide (SiC) and silicon, which are currently themain substrates for growth of group III nitride devices, is extremelydifficult.

For light emitting devices, such as light emitting diodes (LEDs) andespecially deep ultraviolet LEDs (DUV LEDs), minimizing a dislocationdensity and a number of cracks in the semiconductor layers increases theefficiency of the device. In addition, it can lead to increasedreliability of the device. To this extent, several approaches havesought to grow low-defect semiconductor layers on patterned substrates.These approaches typically rely on reducing stresses present inepitaxially grown semiconductor layers.

For example, one approach to reduce stress accumulation in anepitaxially grown layer relies on patterning the underlying substrateusing microchannel epitaxy (MCE). Using MCE, a narrow channel is used asa nucleation center containing low defect information from thesubstrate. An opening in a mask acts as a microchannel, which transferscrystal information to the overgrown layer, while the mask preventsdislocations from transferring to the overgrown layer. As a result, theovergrown layer can become dislocation free. The three-dimensionalstructure of the MCE also provides another advantage to stress release.The residual stress can be released effectively since the overgrownlayer easily deforms. In another approach, a mask is applied at alocation of a large concentration of dislocation densities to blocktheir further propagation.

Other approaches rely on epitaxially growing a group III nitride basedsemiconductor superlattice. A superlattice structure mitigates thestrain difference between an aluminum nitride (AlN)/sapphire templateand the subsequent thick Al_(x)Ga_(1-x)N (where 0≦x≦1) layers. Fordevices such as DUV LEDs, thick AlGaN epitaxial layers (e.g., on theorder of a few micrometers) are desirable to reduce current crowding.Using a superlattice approach, an AlN/AlGaN superlattice was grown toreduce biaxial tensile strain and a 3.0 μm-thick Al_(0.2)Ga_(0.8)N wasachieved on sapphire without any cracks. Such a superlattice can be usedto minimize the dislocation density due to varying stresses in thesub-layers of the superlattice elements.

While the superlattice approaches allow some control of tensile andcompressive stresses in epitaxially grown nitride semiconductor layers,the approaches do not enable epitaxial growth of nitride basedsemiconductor layers with uniform composition. Based on previousexperience obtained from gallium nitride (GaN) growth, lateral epitaxialovergrowth (LEO) has proven an efficient way for significant reductionof dislocation in GaN films. Several other technologies evolved fromLEO, such as pendeo-epitaxial, cantilever epitaxy, and facet controlledLEO, have also been developed. While the above approaches work well forepitaxial growth of GaN semiconductor layers, epitaxial growth ofaluminum nitride (AlN) layers is more challenging due to a relativelysmall lateral growth of AlN films.

Another leading approach includes growth of AlN films over patternedsubstrates, such as, for example, patterned sapphire substrate (PSS).While the PSS-based approach generally produces an AlN layer withreduced stress and low dislocation densities, the patterning process andsubsequent growth of AlN films is technologically complicated andcostly.

SUMMARY OF THE INVENTION

Aspects of the invention provide a semiconductor structure comprising abuffer structure and a set of semiconductor layers formed adjacent to afirst side of the buffer structure. The buffer structure can have aneffective lattice constant and a thickness such that an overall stressin the set of semiconductor layers at room temperature is compressiveand is in a range between approximately 0.1 gigapascal (GPa) and 2.0GPa. The buffer structure can be grown using a set of growth parametersselected to achieve the target effective lattice constant a, controlstresses present during growth of the buffer structure, and/or controlstresses present after the semiconductor structure has cooled.

A first aspect of the invention provides a semiconductor structurecomprising: a buffer structure; and a set of semiconductor layers formedadjacent to a first side of the buffer structure, wherein the bufferstructure has an effective lattice constant and a thickness such that anoverall stress in the set of semiconductor layers at room temperature iscompressive and is in a range between approximately 0.1 GPa and 2.0 GPa.

A second aspect of the invention provides a method of fabricating asemiconductor structure, the method including: selecting a set of growthparameters for growing a buffer structure, wherein the set of growthparameters are configured to achieve a target effective lattice constanta for the buffer structure; growing the buffer structure using theselected set of growth parameters; and growing a set of semiconductorlayers on the buffer structure, wherein the target effective latticeconstant a causes an overall stress in the set of semiconductor layersat room temperature to be compressive and in a range betweenapproximately 0.1 GPa and approximately 2.0 GPa.

A third aspect of the invention provides a method of fabricating asemiconductor device, the method including: fabricating a semiconductorheterostructure for the semiconductor device, the fabricating including:growing a buffer layer directly on a substrate using a multi-stageprocess, wherein the multi-stage process includes: growing a pluralityof nucleation islands formed of a group III nitride material on thesubstrate using a V/III ratio configured to form relatively smallislands and a growth duration selected to increase a density of theplurality of nucleation islands, wherein the V/III ratio is in a rangebetween approximately 100 to approximately 50000, and wherein theduration is in a range of approximately one minute to approximatelytwenty minutes; inducing vertical growth of the plurality of nucleationislands using an increased growth temperature; and coalescing theplurality of nucleation islands into a single layer using a high growthtemperature, wherein the single layer is grown to a thickness in a rangeof approximately 100 Angstroms to approximately 100 microns; and growinga set of group III nitride semiconductor layers on the buffer layer,wherein an overall stress in the set of group III nitride semiconductorlayers at room temperature is compressive and in a range betweenapproximately 0.1 GPa and approximately 2.0 GPa.

The illustrative aspects of the invention are designed to solve one ormore of the problems herein described and/or one or more other problemsnot discussed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the disclosure will be more readilyunderstood from the following detailed description of the variousaspects of the invention taken in conjunction with the accompanyingdrawings that depict various aspects of the invention.

FIG. 1 shows a schematic structure of an illustrative optoelectronicdevice according to an embodiment.

FIGS. 2A and 2B show top views of illustrative nucleation islands grownon a substrate according to embodiments.

FIGS. 3A-3C show an illustrative multi-stage process for growing abuffer layer according to an embodiment.

FIG. 4 shows an atomic force microscope image of a top surface of anillustrative buffer layer grown using a three-stage growth processdescribed herein according to an embodiment.

FIG. 5 shows an illustrative heterostructure including an intermediatelayer and an n-type layer according to an embodiment

FIG. 6 shows an illustrative heterostructure including an active regionaccording to an embodiment.

FIG. 7 shows an illustrative heterostructure including a first p-typelayer according to an embodiment.

FIG. 8 shows an illustrative heterostructure including a superlattice asan intermediate layer according to an embodiment.

FIG. 9 shows illustrative plots of the lattice constants a and c as afunction of the V/III ratio for an AlN layer according to an embodiment.

FIG. 10 shows illustrative plots of stress and strain as a function ofthe V/III ratio for an AlN layer according to an embodiment.

FIGS. 11A-11B show illustrative intermediate layers according toembodiments.

FIG. 12 shows various plots of the lattice constant a as a function ofcentral displacement (bowing) during growth of an AlN layer and as afunction of aluminum molar fraction in an AlGaN layer according toembodiments.

FIG. 13 shows an illustrative flow diagram for fabricating a circuitaccording to an embodiment.

It is noted that the drawings may not be to scale. The drawings areintended to depict only typical aspects of the invention, and thereforeshould not be considered as limiting the scope of the invention. In thedrawings, like numbering represents like elements between the drawings.

DETAILED DESCRIPTION OF THE INVENTION

As indicated above, aspects of the invention provide a semiconductorstructure comprising a buffer structure and a set of semiconductorlayers formed adjacent to a first side of the buffer structure. Thebuffer structure can have an effective lattice constant and a thicknesssuch that an overall stress in the set of semiconductor layers at roomtemperature is compressive and is in a range between approximately 0.1GPa and 2.0 GPa. The buffer structure can be grown using a set of growthparameters selected to achieve the target effective lattice constant a,control stresses present during growth of the buffer structure, and/orcontrol stresses present after the semiconductor structure has cooled.

As described herein, the buffer structure can be configured to reduceinternal stresses in the heterostructure, which can lead to improvedreliability of the device. The buffer structure, as well as other layersof the heterostructure, can be grown using growth parameters configuredto control the stresses present during growth. Furthermore, areliability of the device depends on a number of dislocations present inthe layers. In general, for thick layers, a dislocation density issubstantially reduced due to layer relaxation through dislocationannihilation and bending. However, thick semiconductor layers can leadto increased stresses. As a result, design of a heterostructuretypically requires a balance between stresses in the layers and a numberof dislocations. However, for reliable devices, some number ofdislocations may be preferred to be present as they may result inoverall relaxation of the device.

As used herein, unless otherwise noted, the term “set” means one or more(i.e., at least one) and the phrase “any solution” means any now knownor later developed solution. As used herein, unless otherwise noted, theterm “set” means one or more (i.e., at least one) and the phrase “anysolution” means any now known or later developed solution. As usedherein, two materials have comparable compositions when the molarfractions of the corresponding materials differ by at most ten percent(five percent in a more specific embodiment). For example, consideringtwo group III nitride materials, Al_(x)In_(y)B_(z)Ga_(1-x-y-z)N andAl_(x′)In_(y′)B_(z′), Ga_(1-x′-y′-z′)N, the two materials havecomparable compositions when each of the molar fractions x, y, and zdiffers from the corresponding molar fractions x′, y′, and z′ by lessthan ten percent, where the percentage is calculated by taking adifference between the molar fractions and dividing the value by thehigher molar fraction. Similarly, two layers have comparable thicknesseswhen the corresponding thicknesses differ by at most ten percent (fivepercent in a more specific embodiment). As also used herein, two dopantconcentrations are comparable when they are on the same order as oneanother. It is understood that two numbers are on the same order as oneanother when a ratio of the higher number to the lower number is lessthan ten.

As used herein, a layer is a “transparent” layer when the layer allowsat least ten percent of radiation having a target wavelength, which isradiated at a normal incidence to an interface of the layer, to passthere through. Furthermore, as used herein, a layer is a “reflective”layer when the layer reflects at least ten percent of radiation having atarget wavelength, which is radiated at a normal incidence to aninterface of the layer. In an embodiment, the target wavelength of theradiation corresponds to a wavelength of radiation emitted or sensed(e.g., peak wavelength+/−five nanometers) by a device including thelayer during operation of the device. For a given layer, the wavelengthcan be measured in a material of consideration and can depend on arefractive index of the material.

Aspects of the invention provide a heterostructure that can beincorporated into (used to fabricate) an optoelectronic device, such asa conventional or super luminescent light emitting diode (LED), a lightemitting laser, a laser diode, a light sensor, a photodetector, aphotodiode, an avalanche diode, and/or the like. However, it isunderstood that optoelectronic devices are only illustrative. Forexample, aspects of the invention provide a heterostructure that can beincorporated into other types of electronic devices, such as a highelectron mobility transistor, a field effect transistor, a p-n diode, aSchottky diode, or the like. To this extent, aspects of the inventioncan be applied to the fabrication of any type of device in whichcontrolling stress characteristics are important for crack anddislocation reduction. In particular, for light emitting diodesfabricated using group III nitride semiconductor layers, the control ofstress and dislocations within and in proximity of the active layer canprovide improved device operation, extended operating lifetime of thedevice, and/or the like.

Turning to the drawings, FIG. 1 shows a schematic structure of anillustrative optoelectronic device 10 according to an embodiment. In amore particular embodiment, the optoelectronic device 10 is configuredto operate as an emitting device, such as a light emitting diode (LED).In this case, during operation of the optoelectronic device 10,application of a bias comparable to the band gap results in the emissionof electromagnetic radiation from an active region 18 of theoptoelectronic device 10. The electromagnetic radiation emitted by theoptoelectronic device 10 can have a peak wavelength within any range ofwavelengths, including visible light, ultraviolet radiation, deepultraviolet radiation, infrared light, and/or the like. In anembodiment, the device 10 is configured to emit radiation having adominant wavelength within the ultraviolet range of wavelengths. In amore specific embodiment, the dominant wavelength is within a range ofwavelengths that includes deep ultraviolet radiation, e.g., betweenapproximately 210 and approximately 350 nanometers.

The optoelectronic device 10 includes a heterostructure comprising asubstrate 12 and a buffer structure 13 located adjacent thereto. Thebuffer structure 13 is shown including a buffer layer 14 adjacent to thesubstrate 12 and an intermediate layer 15 adjacent to the buffer layer14. The optoelectronic device 10 further includes an n-type layer 16(e.g., a cladding layer, electron supply layer, contact layer, and/orthe like) adjacent to the buffer structure 13, and an active region 18having an n-type side 19A adjacent to the n-type layer 16. Furthermore,the heterostructure of the optoelectronic device 10 includes a firstp-type layer 20 (e.g., an electron blocking layer) adjacent to a p-typeside 19B of the active region 18 and a second p-type layer 22 (e.g., acladding layer, hole supply layer, contact layer, and/or the like)adjacent to the first p-type layer 20.

In a more particular illustrative embodiment, the optoelectronic device10 is a group III-V materials based device, in which some or all of thevarious layers are formed of elements selected from the group III-Vmaterials system. In a still more particular illustrative embodiment,the various layers of the optoelectronic device 10 are formed of groupIII nitride based materials. Group III nitride materials comprise one ormore group III elements (e.g., boron (B), aluminum (Al), gallium (Ga),and indium (In)) and nitrogen (N), such thatAl_(x)Ga_(y)B_(z)In_(1-x-y-z)N, where 0≦x, y, z≦1 and 0≦1-x-y-z≦1.Illustrative group III nitride materials include binary, ternary andquaternary alloys such as, AlN, GaN, InN, BN, AlGaN, AlInN, AlBN,AlGaInN, AlGaBN, AlInBN, and AlGaInBN with any molar fraction of groupIII elements.

An illustrative embodiment of a group III nitride based optoelectronicdevice 10 includes an active region 18 (e.g., a series of alternatingquantum wells and barriers) composed of In_(y)Al_(x)Ga_(1-x-y)N,Ga_(z)In_(y)Al_(x)B_(1-x-y-z)N, an Al_(x)Ga_(1-x)N semiconductor alloy,or the like. Similarly, both the n-type layer 16 and the first p-typelayer 20 can be composed of an In_(y)Al_(x)Ga_(1-x-y)N alloy, aGa_(z)In_(y)Al_(x)B_(1-x-y-z)N alloy, or the like. The molar fractionsgiven by x, y, and z can vary between the various layers 16, 18, and 20.The substrate 12 can be sapphire, silicon carbide (SiC), silicon (Si),GaN, AlGaN, AlON, LiGaO₂, LiGaO₂, ScMgAlO₄, MgAl₂O₄, or another suitablematerial, and each of the buffer layer 14 and intermediate layer 15 canbe composed of AlN, InN, GaN, SiN, or their alloys, an AlGaN/AlNsuperlattice, and/or the like.

As shown with respect to the optoelectronic device 10, a p-type metal 24can be attached to the second p-type layer 22 and a p-type contact(electrode) 26 can be attached to the p-type metal 24. Similarly, ann-type metal 28 can be attached to the n-type layer 16 and an n-typecontact (electrode) 30 can be attached to the n-type metal 28. Thep-type metal 24 and the n-type metal 28 can form ohmic contacts to thecorresponding layers 22, 16, respectively. In an embodiment, the p-typemetal 24 and the n-type metal 28 each comprise several conductive andreflective metal layers, while the n-type contact 30 and the p-typecontact 26 each comprise highly conductive metal. In an embodiment, thesecond p-type layer 22 and/or the p-type contact 26 can be transparent(e.g., semi-transparent or transparent) to the electromagnetic radiationgenerated by the active region 18. For example, the second p-type layer22 and/or the p-type contact 26 can comprise a short period superlatticelattice structure, such as an at least partially transparent magnesium(Mg)-doped AlGaN/AlGaN short period superlattice structure (SPSL). In anillustrative embodiment, the second p-type layer 22 is a superlatticecomprising Al_(x)Ga_(1-x)N/Al_(y)Ga_(1-y)N layers, with 0.2<x<1, and0<y<0.8, and with each layer of the superlattice having a thickness inthe range of 0.1 to 20 nanometers. Furthermore, the p-type contact 26and/or the n-type contact 30 can be reflective of the electromagneticradiation generated by the active region 18. In another embodiment, then-type layer 16 and/or the n-type contact 30 can be formed of a shortperiod superlattice, such as an AlGaN SPSL, which is transparent to theelectromagnetic radiation generated by the active region 18.

As further shown with respect to the optoelectronic device 10, thedevice 10 can be mounted to a submount 36 via the contacts 26, 30 in aflip chip configuration. In this case, the substrate 12 is located onthe top of the optoelectronic device 10, which can provide improved heatmanagement during operation of the device 10. To this extent, the p-typecontact 26 and the n-type contact 30 can both be attached to a submount36 via contact pads 32, 34, respectively. The submount 36 can be formedof aluminum nitride (AlN), silicon carbide (SiC), and/or the like.

Any of the various layers of the optoelectronic device 10 can comprise asubstantially uniform composition or a graded composition. For example,a layer can comprise a graded composition at a heterointerface withanother layer. In an embodiment, the first p-type layer 20 comprises ap-type electron blocking layer having a graded composition. The gradedcomposition(s) can be included to, for example, reduce stress, improvecarrier injection, and/or the like. Similarly, a layer can comprise asuperlattice including a plurality of periods, which can be configuredto reduce stress, and/or the like. In this case, the composition and/orwidth of each period can vary periodically or aperiodically from periodto period.

It is understood that the layer configuration of the optoelectronicdevice 10 described herein is only illustrative. To this extent, aheterostructure for an optoelectronic device can include an alternativelayer configuration in which one or more layers are not included and/orone or more additional layers are included. As a result, while thevarious layers are shown immediately adjacent to one another (e.g.,contacting one another), it is understood that one or more intermediatelayers can be present in a heterostructure for an optoelectronic deviceand/or one or more of the layers shown may not be present. For example,an illustrative heterostructure for an optoelectronic device can includean undoped layer between the active region 18 and one or both of thesecond p-type layer 22 and the n-type layer 16. Similarly, anillustrative heterostructure for an optoelectronic device can beimplemented without the intermediate layer 15, with the substrate 12removed, and/or the like.

Still further, an alternative device heterostructure can include three(or more) p-type layers located on the p-type side 19B of the activeregion 18. For example, the p-type layers can include: an electronblocking layer (e.g., the first p-type layer 20) located immediatelyadjacent to the active region 18; a p-type cladding layer (e.g., thesecond p-type layer 22) located immediately adjacent to the electronblocking layer; and a p-type doping layer located immediately adjacentto the p-type cladding layer (e.g., between the second p-type layer 22and the p-type metal 24). In this case, each p-type layer can beepitaxially grown on a preceding layer. In a more particular embodiment,the p-type doping layer can be formed of Al_(x)Ga_(1-x)N, where 0≦x≦0.5,can have a thickness in a range of 1 nanometer to 500 nanometers, andcan have a p-type doping concentration greater than or equal to 1×10¹⁸dopants per cm³.

Furthermore, a heterostructure for an optoelectronic device can includea Distributive Bragg Reflector (DBR) structure, which can be configuredto reflect light of particular wavelength(s), such as those emitted bythe active region 18, thereby enhancing the output power of thedevice/heterostructure. For example, for the flip chip configurationillustrated, the DBR structure can be located between the second p-typelayer 22 and the active region 18. Similarly, a heterostructure for anoptoelectronic device can include a first p-type layer 20 locatedbetween the second p-type layer 22 and the active region 18. The DBRstructure and/or the first p-type layer 20 can have any compositionselected based on a desired wavelength of the light generated by thedevice. In one embodiment, the DBR structure has a Mg, Mn, Be, orMg+Si-doped p-type composition. The first p-type layer 20 can have ap-type AlGaN, AlInGaN, and/or the like. It is understood that aheterostructure for an optoelectronic device can include both the DBRstructure and the first p-type layer 20 (which can be located betweenthe DBR structure and the second p-type layer 22) or can include onlyone of the DBR structure or the first p-type layer 20. In an embodiment,the first p-type layer 20 can be included in the device/heterostructurein place of an electron blocking layer. In another embodiment, the firstp-type layer 20 can be included between the second p-type layer 22 andthe electron blocking layer.

In an embodiment, each of the layers 14, 15, 16, 18, 20, 22 areepitaxially grown on the substrate 12. Illustrative growth parametersfor group III nitride layers 14, 15, 16, 18, 20, 22 can include: a groupIII precursor flow rate between approximately 0.1 and approximately 200micromoles per minute; a nitrogen precursor flow rate betweenapproximately 100 and 10000 standard cubic centimeters per minute(SCCM); and a pressure between approximately 1 and 760 Torr.

In an embodiment, the buffer layer 14 is configured to relieve stress inthe set of semiconductor layers located on a side of the buffer layer 14opposite the location of the substrate 12, e.g., in the intermediatelayer 15, the n-type layer 16, the active region 18, the p-type layers20, 22, and/or the like. To this extent, the buffer layer 14 can have aneffective lattice constant such that, when measured at room temperature,an overall stress in the buffer layer 14 is both compressive and small.As used herein, a compressive stress is small when the stress is lessthan or equal to approximately two GPa. In an embodiment, when measuredat room temperature, the set of semiconductor layers has a compressivestress in a range between approximately 0.1 GPa and approximately 2.0GPa. For example, the compressive stress can be estimated using thebowing of the substrate wafer over which the epitaxial film is grown.The bowing is characterized by the displacement of the middle of thewafer relative to the edge of the wafer. An illustrative growth processfor a buffer layer 14 described herein can use growth temperatures in arange between approximately 500° C. and approximately 1500° C. and agrowth rate between approximately 0.01 micrometers per hour andapproximately 10 micrometers per hour.

In an embodiment, the buffer layer 14 is grown using a multi-stageprocess in order to obtain the small compressive stress in the bufferlayer 14. In a first stage of the process, a plurality of nucleationislands are grown on the surface of the substrate 12. During the firststage, various attributes of the nucleation islands can be controlled byvarying one or more growth conditions used during growth of thenucleation islands. Illustrative attributes include: an average size ofthe nucleation islands; a density of the nucleation islands (e.g., anaverage separation distance); an average ratio of vertical size tolateral size of the nucleation islands; and/or the like. Illustrativegrowth conditions that can be varied include: a growth temperature; aratio of group V precursor(s) to group III precursor(s) (the V/IIIratio); a growth duration; a growth pressure; and/or the like. Furtherdiscussion of illustrative growth conditions assumes a growth pressurein a range between approximately 1 Torr and approximately 760 Torr.However, it is understood that this is only illustrative. Additionally,a growth process described herein is described in conjunction withgrowth of an AlN buffer layer 14. However, it is understood that asimilar growth process can be utilized to form a layer (which may or maynot be a buffer layer 14) of another type of material and/or acombination of two or more materials.

FIGS. 2A and 2B show top views of illustrative nucleation islands grownon a substrate according to embodiments. The nucleation islands 14A, 14Bshown in FIG. 2A are relatively small and relatively densely packed ascompared to the nucleation islands 14C, 14D shown in FIG. 2B. Thenucleation islands 14A, 14B of FIG. 2A can result from a nucleationgrowth mode characterized by relatively low temperatures in a range ofapproximately 600° C. to approximately 1100° C. and an extended durationbetween approximately one minute and approximately twenty minutes. Thenucleation islands 14C, 14D of FIG. 2B can result from an alternativenucleation growth mode characterized by temperatures in a range ofapproximately 1100° C. to approximately 1300° C. and a duration ofapproximately ten minutes or more.

In general, coalescence of small nucleation islands can result inincreased tensile stresses. Under such a growth condition, onlyrelatively thin layers of aluminum nitride can be produced without thegeneration of cracks. Growth of only a few nucleation islands can belead to lower tensile stresses, or in some cases, to small compressivestresses during subsequent growth. However, while low tensile stressescan be beneficial during the growth of a semiconductor layer, subsequentlarge compressive stresses developed during cooling can severely affecta quality of the material, reducing overall reliability of the resultingdevices.

Changes in the V/III ratio during the growth of nucleation islands canlead to variation in a lattice constant of the resulting buffer layer 14(FIG. 1) and to generation of voids and/or nano-cavities within thelayer. Such voids/nano-cavities can further affect the elasticproperties of the resulting buffer layer 14, making it “softer” and morereadily capable of absorbing stresses due to subsequently grownepitaxial layers. In addition, as the V/III ratio increases, a verticalgrowth rate is enhanced and a lateral growth rate is restrained.

In an embodiment, the inventors propose to select a target size and atarget density of the nucleation islands, which facilitate more readilycontrol over tensile stresses within the resulting buffer layer. Duringgrowth of the nucleation islands 14A-14D, the inventors propose tocontrol a typical size of the nucleation islands 14A-14D by adjusting aV/III ratio used during the growth. Furthermore, the inventors proposeto increase a density of the nucleation islands 14A-14D by increasing aduration of the nucleation island growth. The number of nucleationislands 14A-14D can be adjusted by adjusting one or more growthparameters including: a duration of the epitaxial growth; a flow set forvarious metalorganic precursors; a growth temperature; a growthpressure; a ratio of group V precursors to group III precursors; and/orthe like. An illustrative growth process for growth of an AlN bufferlayer 14 is described herein. However, it is understood that similartechniques but with different growth conditions (e.g., ranges fortemperature and V/III ratio) can be applied to growth of any of variousAl_(x)In_(y)Ga_(1-x-y)N alloy layers.

FIGS. 3A-3C show an illustrative multi-stage process for growing abuffer layer according to an embodiment. As described herein, in thefirst stage shown in FIG. 3A, a plurality of nucleation islands 14A-14Bcan be grown on a substrate 12. In an embodiment, the nucleation islands14A-14B are formed of a similar material (e.g., AlN). Alternatively, thenucleation islands 14A-14B can be formed of multiple dissimilarmaterials, such as any combination of two or more of: InN, GaN, AlN,SiN, or their alloys. Introduction of nucleation islands 14A-14B formedof dissimilar materials can allow for additional control of stresseswithin the buffer structure, which can lead to overall improvement instress management of subsequently grown semiconductor layers.

The growth conditions used during the first stage can induce threedimensional growth of the nucleation islands 14A-14B. In an embodiment,the resulting nucleation islands 14A-14B have a typical (e.g., average)size in a range between approximately 1 nanometer and approximately 100nanometers and a typical (e.g., average) spacing, as measured fromedge-to-edge between adjacent islands, in a range between approximately10 nanometers and approximately 200 nanometers. In an embodiment, thegrowth conditions include: a relatively low temperature in a range ofapproximately 600° C. to approximately 1300° C. (1100° C. in a moreparticular embodiment); a relatively high V/III ratio in a range ofapproximately 100 to approximately 50000; and an extended duration in arange of approximately one minute to approximately twenty minutes.

In a second stage of the growth process, which is shown in FIG. 3B,growth conditions that induce vertical growth of the nucleation islands14A-14B can be utilized. For example, a growth temperature can beincreased, a high V/III ratio can be utilized, and a precursor flow ratecan be changed (e.g., decreased) to a range of approximately 1micromole/minute and approximately 100 micromoles/minute. In anembodiment, the growth conditions for the second stage include: arelatively high temperature in a range of approximately 1000° C. toapproximately 1300° C.; a relatively high V/III ratio in a range ofapproximately 1000 to approximately 50000; and a duration ofapproximately 1 hour to approximately 10 hours. In an embodiment, thenucleation islands 14A-14B are grown to a height in a range ofapproximately 5 Angstroms to approximately 100 Angstroms.

In a third stage of the growth process, which is shown in FIG. 3C,growth conditions that result in coalescence of the nucleation islands14A-14B into a single layer 14 can be utilized. For example, a growthtemperature can be again increased and a low V/III ratio can beutilized. In an embodiment, the growth conditions for the third stageinclude: a relatively high temperature in a range of approximately 1100°C. to approximately 1600° C.; a relatively low V/III ratio in a range ofapproximately 1 to approximately 2500; and a duration sufficient toallow the coalesced islands 14A-14B to grow to a thickness in a range ofapproximately 100 Angstroms to approximately 100 microns. During thethird stage, a small molar fraction (e.g., one to five percent) ofgallium can be added within the semiconductor layer, which can furtherincrease coalescence of the nucleation islands 14A-14B. The stressespresent during the nucleation island coalescence can be tensile. In anembodiment, the growth conditions described herein are selected toresult in small tensile stresses being present during growth of thebuffer layer 14, and reasonably small compressive stresses at roomtemperature.

After completion of the third stage, the nucleation islands 14A-14B canbe fully coalesced into a pit-free, single-crystalline semiconductor(e.g., AlN) layer. As illustrated, the resulting buffer layer 14includes at least two distinct sublayers, a nucleation sublayer, whichincludes the nucleation islands 14A-14B and a high temperature growthsublayer, in which the nucleation islands 14A-14B have coalesced.

In an embodiment, the multi-stage growth process shown in FIGS. 3A-3C isrepeated two or more times to produce various sub-layers of variableelastic and thermo-mechanical properties for stress management withinthe buffer layer 14. In this case, each repeated application of themulti-stage growth process can utilize the same growth conditions as aprevious application or can utilize one or more differing growthconditions (e.g., a change in growth duration, a change in V/III ratio,and/or the like.

FIG. 4 shows an atomic force microscope (AFM) image of a top surface ofan illustrative buffer layer grown using a three-stage growth processdescribed herein according to an embodiment. As illustrated, the bufferlayer has an extremely flat surface morphology. In particular, an atomicstep shows an RMS of approximately 1.0 Angstroms with a 5 μm×5 μm scan.Furthermore, an embodiment of a buffer layer grown using a solutiondescribed herein can have approximately 1×10⁹ dislocation cores per cm²or less.

Additional layers of a heterostructure can be formed (e.g., grown) onthe buffer layer 14. To this extent, FIG. 5 shows an illustrativeheterostructure 11A including an intermediate layer 15 and an n-typelayer 16 according to an embodiment. As illustrated, the heterostructure11A includes a substrate 12 with a buffer layer 14 formed thereon. Theintermediate layer 15 can be located between the buffer layer 14 and ann-type layer 16 (e.g., an n-type contact layer). As illustrated in FIG.6, fabrication of a heterostructure 11B can include growth of the n-typelayer 16 followed by epitaxial growth of an active region 18, which caninclude a plurality of quantum wells (dark sub-layers) alternating witha plurality of barriers (light sub-layers).

The intermediate layer 15 can be configured to: further mitigatepropagation of dislocations from the buffer layer 14 to the n-type layer16 and active region 18; relax layers, such as the n-type contact layer16 and active region 18, which are subsequently epitaxially grown;and/or the like. For example, as illustrated by the vertically extendinglines shown in heterostructures 11A, 11B, the intermediate layer 15 caninclude a large number of dislocations, which can result in relaxationin the subsequently grown layers, such as the n-type layer 16. Asfurther illustrated, some of the dislocations present in the bufferlayer 14 will terminate and not extend into the intermediate layer 15,and similarly, some of the dislocations present in the intermediatelayer 15 will terminate and not extend into the n-type layer 16. Thecircles shown in FIGS. 5 and 6 indicate regions where a dislocation islocated. In the drawings, the dislocations are lying into the plane,with each circle corresponding to a core of such dislocations. These areedge dislocations and they are propagated in a lateral direction on theplane. In an embodiment, a thickness of the buffer layer 14 and athickness of the intermediate layer 15 are selected to result in atarget amount of relaxation in the subsequent semiconductor layers. Inan embodiment, the n-type layer 16 is a partially relaxed layer. Forexample, a thickness of each of the buffer layer 14 and the intermediatelayer 15 can be on the order of one micron (e.g., 0.1 microns to 10microns). In an illustrative embodiment, a threading dislocation densitywithin the active region 18 is in a range of approximately 1×10³ toapproximately 5×10⁹ threading dislocations per cm².

Formation of the layers of a heterostructure can further continue on thep-type side of the active region 18. For example, FIG. 7 shows anillustrative heterostructure 11C including a first p-type layer 20(e.g., an electron blocking layer), which can be grown on the activestructure 18, according to an embodiment. As illustrated in FIG. 7, theheterostructure 11C can be formed without including an intermediatelayer 15. In this case, the n-type layer 16 can be epitaxially growndirectly on the buffer layer 14. In an embodiment, the n-type layer 16is under compression due to a reduced molar fraction of aluminum in then-type layer 16 as compared to a molar fraction of aluminum in the layeron which the n-type layer 16 is grown, e.g., the buffer layer 14 or theintermediate layer 15.

In an embodiment, a heterostructure can include an intermediate layer 15configured to mitigate compression in the n-type contact layer 16, whichcan reduce a dislocation density in the n-type contact layer 16. Forexample, FIG. 8 shows an illustrative heterostructure 11D including asuperlattice as an intermediate layer 15 according to an embodiment. Inan embodiment, the intermediate layer 15 is a superlattice comprisingAlN layers interchanged with Al_(x)Ga_(1-x)N layers. Each layer of sucha superlattice can have a thickness in a range of approximately 10nanometers (e.g., 5 to 15 nanometers) and the Al_(x)Ga_(1-x)N layers cancontain a molar faction of aluminum, x, as low as approximately 0.7(e.g., in a range of approximately 0.6 to approximately 0.9). Thealuminum molar fraction for the various Al_(x)Ga_(1-x)N layers canremain constant throughout the superlattice or vary over a height of thesuperlattice using any solution (e.g., gradually decrease from thebuffer layer 14 side to the n-type layer 16 side). Furthermore, thesuperlattice can include tens of periods (e.g., approximately 10 toapproximately 100), with each period including an AlN/Al_(x)Ga_(1-x)Npair of layers. In general, a presence of such a superlattice provides areduction dislocation density and mitigates stresses at the sharpinterfaces between semiconductor layers with large (e.g., greater thanten percent) changes in aluminum molar fraction.

In an embodiment, the superlattice of the intermediate layer 15 can begrown using a set of growth conditions configured to manipulate stresseswithin the heterostructure 11D in a target manner. For example, duringgrowth of the superlattice, a V/III ratio can be varied to further alterthe resulting tensile and compressive stresses in each layer of thesuperlattice that results from the varying aluminum molar fraction ofimmediately adjacent layers.

To this extent, FIG. 9 shows illustrative plots of the lattice constantsa and c as a function of the V/III ratio for an AlN layer according toan embodiment. Different lattice directions can result in differenttensile and compressive properties for the AlN layer. For example, for alow V/III ratio (e.g., less than approximately 1800), the latticeconstant a for the AlN layer is slightly larger than the latticeconstant a for an AlN layer without the presence of point defects (e.g.,approximately 3.112). The difference in the lattice constant a resultsin tensile stresses being accumulated in the layer. For a high V/IIIratio (e.g., greater than approximately 1800), the lattice constant afor the AlN layer is slightly smaller than the lattice constant a for anAlN layer without the presence of point defects, which results incompressive stresses being accumulated in the layer. The V/III ratioalso influences the lattice constant c. In this case, small values ofthe V/III ratio (e.g., below approximately 750) result in a latticeconstant c, which causes compressive stress (e.g., is belowapproximately 4.982) in the layer, while larger values of the V/IIIratio (e.g., above approximately 750) result in a lattice constant c,which causes tensile stress in the layer.

FIG. 10 shows illustrative plots of stress and strain as a function ofthe V/III ratio for an AlN layer according to an embodiment. Asillustrated, an AlN layer grown under a low V/III ratio (e.g., less thanapproximately 1800) is in tensile stress, while an AlN layer grown witha high V/III ratio (e.g., above approximately 1800) is in compressivestress. As further illustrated, only small changes in the strain of theAlN layer are produced by modulating the V/III ratio. In an embodiment,growth of the buffer layer 14 uses a set of growth parameters, which areadjusted to decrease local tensile stresses during growth. Furthermore,the set of growth parameters can be configured to limit compressivestress during growth. In an embodiment, the compressive stress islimited to approximately 1.0 GPa or less during the growth.

In an embodiment, growth of the intermediate layer 15 includes growth ofa series of sub-layers (e.g., films) with alternating tensile andcompressive stresses. A layer can be selectively configured to havetensile or compressive stress by modulating a V/III ratio in eachsub-layer. For example, the modulation can include varying the V/IIIratio according to a set schedule to yield compressive and tensilesub-layers. Additionally, one or more additional deposition conditionscan be changed, such as a growth temperature, a gas flow, and/or thelike. Furthermore, one or more attributes of the sub-layers, such as arelative thickness of a sub-layer, a distribution of stress within eachsub-layer, and/or the like, can be adjusted during the growth of thelayer. The modulation of the set of deposition conditions can result inregions of increased compressive stresses and regions of increasedtensile stress. In this manner, the resulting intermediate layer 15 canbe configured to have a target overall residual stress (e.g.,approximately zero or near zero).

FIGS. 11A-11B show illustrative intermediate layers 15A-15B according toembodiments. Each intermediate layer 15A-15B is shown grown on a bufferlayer 14, which can be grown on a substrate 12. In an embodiment, thesubstrate 12 is a foreign substrate, such as sapphire, SiC, or the like.The buffer layer 14 (e.g., a nucleation layer) can provide a transitionto accommodate a large lattice mismatch between the substrate 12 and thecorresponding intermediate layer 15A-15B. In an embodiment, the bufferlayer 14 can comprise an Al_(x)Ga_(1-x)N/Al_(y)Ga_(1-y)N superlattice,where 0≦x, y≦1. Each superlattice layer can be, for example, up toseveral nanometers thick. In an embodiment, the layers with differingaluminum content (e.g., denoted by x and y) can have similarthicknesses. In an illustrative embodiment, the buffer layer 14 has athickness in a range from nearly zero nanometers to approximately 2000nanometers. In another embodiment, growth of the buffer layer 14 uses agrowth temperature between approximately 500 and approximately 1200degrees Celsius and a growth rate between approximately 0.01 micrometersand approximately 10 micrometers per hour.

Regardless, each intermediate layer 15A-15B is formed of a plurality ofcompressive sub-layers 40A-40C alternating with a plurality of tensilesub-layers 42A-42C. In the intermediate layer 15A, a compressivesub-layer 40A is first grown, while in the intermediate layer 15B, atensile sub-layer 42A is first grown. While each intermediate layer15A-15B is shown including three periods of epitaxial growth (e.g., eachperiod including a compressive and a tensile layer), it is understoodthat an intermediate layer 15A-15B can include any number of periods. Inan embodiment, the stress changes abruptly between a compressive layerand the adjacent tensile layer. Alternatively, the stress can graduallychange between adjacent layers (e.g., by growing layers having a gradedtensile or compressive stress). Furthermore, the tensile and compressivestress can be substantially constant between periods of the intermediatelayer 15A-15B or can gradually change from period to period.

The growth of an intermediate layer 15A-15B, and the growth of thecorresponding sub-layers 40A-40C, 42A-42C forming the intermediate layer15A-15B, can use any set of deposition conditions. For example, the setof deposition conditions for a sub-layer 40A-40C, 42A-42C can include: agroup III precursor flow rate between approximately 0.1 andapproximately 200 micromoles per minute; a nitrogen precursor flow ratebetween approximately 100 and 10000 standard cubic centimeters perminute (SCCM); a pressure between approximately 1 and 760 Torr; a molarratio of group V precursors to group III precursors (V/III ratio)between approximately 10 and approximately 10000; and a growthtemperature between approximately 500 and approximately 1800 degreesCelsius. Furthermore, a sub-layer 40A-40C, 42A-42C can be grown to athickness that is greater than a critical thickness to avoidpseudomorphic growth. In an embodiment, each sub-layer 40A-40C, 42A-42Chas a thickness between approximately one nanometer and fivemicrometers.

As described herein, during the growth of an intermediate layer 15A-15B,one or more of a set of the deposition conditions for epitaxiallygrowing a sub-layer 40A-40C, 42A-42C can be changed to cause theresulting sub-layer 40A-40C, 42A-42C to exhibit either tensile orcompressive residual stress. For example, the growth of a compressivesub-layer and the growth of a tensile sub-layer can use molar ratios ofgroup V precursors to group III precursors that differ by at least tenpercent. In an embodiment, a composition of the compressive sub-layerdiffers from a composition of the tensile sub-layer by no more thanapproximately five percent. For example, a fraction of aluminum in thetensile sub-layer can differ from a fraction of aluminum in thecompressive sub-layer by no more than approximately five percent.Similarly, the compressive and tensile sub-layers can have a latticemismatch of at least 0.0001 Angstroms. Furthermore, a growth rate forthe compressive and tensile sub-layers can be changed. In an embodiment,the growth rates for the compressive and tensile sub-layers differ by atleast ten percent. A growth temperature for the compressive and tensilesub-layers can be substantially the same or changed. In an embodiment,the growth temperatures for the compressive and tensile sub-layersdiffer by at least two percent. Still further, the number of and/or typeof precursors and/or agents present during the growth of a sub-layer canbe adjusted to alter elastic properties of the sub-layer. For example,precursors and agents such as: ZnO, TiN, SiN, GaAs, AlAs, GaN, InNand/or the like, can induce inhomogeneities within the sub-layer, andthus alter the elastic properties of the sub-layer.

In an embodiment, a composition of the intermediate layer 15 is selectedbased on an effect of bowing of the substrate 12 on the stresses of thebuffer layer 14. For example, FIG. 12 shows various plots of the latticeconstant a as a function of central displacement (bowing) during growthof an AlN layer (e.g., the buffer layer 14) and as a function ofaluminum molar fraction in an Al_(x)Ga_(1-x)N layer according toembodiments. The plots can be used, for example, to select a compositionof the intermediate layer 15 (e.g., a superlattice forming theintermediate layer 15) that is configured to mitigate stress in an AlNbuffer layer 14 (e.g., having a thickness of approximately 0.5 microns).

As illustrated in FIG. 12, during growth of the buffer layer 14 afterthe nucleation phase, the buffer layer 14 can experience high tensilestresses due to bowing, which can result in an increase of the effectivelattice constant a for the buffer layer 14. The tensile stressescorrelate with an amount of bowing that occurs during the growth of thebuffer layer 14, and can be estimated using a known amount of bowingcorresponding to a growth temperature and the substrate 12. Furthermore,the change in the effective lattice constant a is affected by anestimated biaxial modulus of the buffer layer 14. FIG. 12 includes threeplots corresponding to three different estimated biaxial moduli(M_(AlN)) for an AlN buffer layer 14. In an embodiment, the bowing ismeasured as a displacement of a center of the substrate 12 (e.g., asapphire wafer) used for epitaxial growth of the buffer layer 14. For asapphire wafer, such a measurement can typically range between 10-400microns.

In an embodiment, a composition of an Al_(x)Ga_(1-x)N sub-layer of anAlN/Al_(x)Ga_(1-x)N superlattice forming the intermediate layer 15 isselected based on an estimated biaxial modulus of the buffer layer 14and an amount of bowing (central displacement) that occurs during growthof the buffer layer 14. For example, using an estimated biaxial modulusof 400 GPa and a central displacement of 24 microns, an effectivelattice constant a for an AlN buffer layer 14 can exceed 3.135 A at agrowth temperature of 1300° C. It is understood that the actual latticeconstant a of the AlN buffer layer 14 is subject to nucleation growthconditions and the tensile stresses acquired during such growth. Theresulting lattice constant a of 3.135 A is larger than 3.125 A due tothermal expansion alone. The increased lattice constant a for the bufferlayer 14 is most closely matched at the growth temperature of 1300° C.by an Al_(x)Ga_(1-x)N layer having an aluminum molar fraction ofapproximately 0.8. To this extent, the intermediate layer 15 can includean Al_(0.8)Ga_(0.2)N layer, which can result in low stresses within thelayer at the growth temperature. In an embodiment, the identifiedaluminum molar fraction is used as the aluminum molar fraction in afirst Al_(x)Ga_(1-x)N sub-layer of an AlN/Al_(x)Ga_(1-x)N superlatticeforming the intermediate layer 15. In an alternative embodiment, theidentified aluminum molar fraction is used as an average aluminum molarfraction present in all sub-layers in the superlattice.

An embodiment of the invention provides a process for growing amulti-layer semiconductor structure in which a content of a subsequentlayer is at least partially selected based on stress and strain of theexisting heterostructure. In this case, a curvature of the existingheterostructure can be measured in-situ during and/or after growth of afirst layer (e.g., the buffer layer 14) having a target lattice constanta₁. The measured curvature can be used to determine a stress and strainin the first layer, e.g., using the modified Stoney's formula. Thestress and strain can be used to select/adjust one or more aspects ofthe composition of the next layer to be grown and/or one or more growthparameters. For example, for a group III nitride semiconductor layer,the molar fraction of one or more of the group III elements present inthe semiconductor layer can be adjusted. In an embodiment, the group IIInitride composition is selected to have a target lattice constant a₂when fully relaxed, such that ε₁<(a₂−a₁)/a₁<ε₀ with ε₀ being no morethan 0.5 percent and ε₁ being no less than −0.05 percent. Subsequently,the second layer is grown to have the selected composition. Similarly,one or more growth parameters, such as: temperature, V/III ratio, growthrate, chamber pressure, duration of precursor pulses, type ofprecursors, and/or the like, can be adjusted to affect the bowing of thesubstrate to match predicted bowing values. Such a process of measuringbowing and adjusting a composition of the next layer can be repeated anynumber of times during fabrication of the multi-layer semiconductorstructure.

An embodiment of the process can further include masking variousregions. For example, a set of masking regions can be placed on asubstrate. Subsequently, selective area growth can be performed on theunmasked areas (e.g., 10×10 micron region(s)). Zero or more of the setof masking regions can be removed after the selective growth.Subsequently, a first layer can be grown to have the target effectivelattice constant a₁ and the process can continue as described herein.

It is understood that the design and growth conditions for the bufferlayer 14 and/or the intermediate layer 15 can be further selected basedon the type of device (e.g., optoelectronic or electronic) for which theheterostructure is being fabricated. For example, for fabricating alight emitting diode, different buffer and intermediate layer growthconditions will be used depending on a target wavelength to be emittedby the corresponding light emitting diode. In an embodiment, a thicknessof the buffer layer and/or an aluminum molar fraction in theintermediate layer can increase as an aluminum molar fraction in thequantum wells of the active region of the device increases. For example,when the light emitting device is configured to emit deep ultravioletradiation (e.g., having wavelengths in a range between 240-270nanometers), the thickness of the buffer layer and/or the aluminum molarfraction of the intermediate layer can be larger than those used for alight emitting diode configured to emit radiation having a wavelength ina range between 270-310 nanometers, which requires a smaller aluminummolar fraction in the active region. As an illustrative comparison, forfabricating a light emitting diode configured to operate at 280 nmwavelength, the intermediate layer can comprise a superlattice ofalternating AlN/Al_(x)Ga_(1-x)N layers with an aluminum molar fractionx=0.8, whereas for fabricating a light emitting diode configured tooperate at 310 nm wavelength, the intermediate layer can comprise asuperlattice of alternating AlN/Al_(x)Ga_(1-x)N layers with x less than0.7.

A heterostructure described herein can be fabricated using any solution.For example, the various semiconductor layers described herein can begrown over a substrate using an epitaxial growth procedure. As describedherein, one or more of the growth conditions utilized for a layer can beconfigured to create a desired property for the layer. For example, whena layer includes a superlattice, the growth conditions of such asuperlattice can affect the stresses and strains in the superlatticelayers. In particular, such a superlattice can comprise compressive andtensile layers that can further control the distribution of stressesthroughout the heterostructure. Furthermore, the tuning of stresses andstrains can be achieved by controlling the epitaxial growth parametersof a semiconductor layer. For example, by inducing three-dimensionalgrowth of a semiconductor layer, the resulting layer can exhibitcompositional and/or doping concentration inhomogeneities that canaffect the resulting stresses and strains within the layer. Furthermore,such inhomogeneities can result in regions that are highly transparentinterchanging with regions that are highly conductive, where the term“highly” is understood as being a relative term when comparing thetransparent or conductive properties of the different regions within thesemiconductor layer.

In one embodiment, the invention provides a method of designing and/orfabricating a circuit that includes one or more of the devices designedand fabricated as described herein. To this extent, FIG. 13 shows anillustrative flow diagram for fabricating a circuit 126 according to anembodiment. Initially, a user can utilize a device design system 110 togenerate a device design 112 for a semiconductor device as describedherein. The device design 112 can comprise program code, which can beused by a device fabrication system 114 to generate a set of physicaldevices 116 according to the features defined by the device design 112.Similarly, the device design 112 can be provided to a circuit designsystem 120 (e.g., as an available component for use in circuits), whicha user can utilize to generate a circuit design 122 (e.g., by connectingone or more inputs and outputs to various devices included in acircuit). The circuit design 122 can comprise program code that includesa device designed as described herein. In any event, the circuit design122 and/or one or more physical devices 116 can be provided to a circuitfabrication system 124, which can generate a physical circuit 126according to the circuit design 122. The physical circuit 126 caninclude one or more devices 116 designed as described herein.

In another embodiment, the invention provides a device design system 110for designing and/or a device fabrication system 114 for fabricating asemiconductor device 116 as described herein. In this case, the system110, 114 can comprise a general purpose computing device, which isprogrammed to implement a method of designing and/or fabricating thesemiconductor device 116 as described herein. Similarly, an embodimentof the invention provides a circuit design system 120 for designingand/or a circuit fabrication system 124 for fabricating a circuit 126that includes at least one device 116 designed and/or fabricated asdescribed herein. In this case, the system 120, 124 can comprise ageneral purpose computing device, which is programmed to implement amethod of designing and/or fabricating the circuit 126 including atleast one semiconductor device 116 as described herein.

In still another embodiment, the invention provides a computer programfixed in at least one computer-readable medium, which when executed,enables a computer system to implement a method of designing and/orfabricating a semiconductor device as described herein. For example, thecomputer program can enable the device design system 110 to generate thedevice design 112 as described herein. To this extent, thecomputer-readable medium includes program code, which implements some orall of a process described herein when executed by the computer system.It is understood that the term “computer-readable medium” comprises oneor more of any type of tangible medium of expression, now known or laterdeveloped, from which a stored copy of the program code can beperceived, reproduced, or otherwise communicated by a computing device.

In another embodiment, the invention provides a method of providing acopy of program code, which implements some or all of a processdescribed herein when executed by a computer system. In this case, acomputer system can process a copy of the program code to generate andtransmit, for reception at a second, distinct location, a set of datasignals that has one or more of its characteristics set and/or changedin such a manner as to encode a copy of the program code in the set ofdata signals. Similarly, an embodiment of the invention provides amethod of acquiring a copy of program code that implements some or allof a process described herein, which includes a computer systemreceiving the set of data signals described herein, and translating theset of data signals into a copy of the computer program fixed in atleast one computer-readable medium. In either case, the set of datasignals can be transmitted/received using any type of communicationslink.

In still another embodiment, the invention provides a method ofgenerating a device design system 110 for designing and/or a devicefabrication system 114 for fabricating a semiconductor device asdescribed herein. In this case, a computer system can be obtained (e.g.,created, maintained, made available, etc.) and one or more componentsfor performing a process described herein can be obtained (e.g.,created, purchased, used, modified, etc.) and deployed to the computersystem. To this extent, the deployment can comprise one or more of: (1)installing program code on a computing device; (2) adding one or morecomputing and/or I/O devices to the computer system; (3) incorporatingand/or modifying the computer system to enable it to perform a processdescribed herein; and/or the like.

The foregoing description of various aspects of the invention has beenpresented for purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed, and obviously, many modifications and variations arepossible. Such modifications and variations that may be apparent to anindividual in the art are included within the scope of the invention asdefined by the accompanying claims.

What is claimed is:
 1. A semiconductor structure comprising: a bufferstructure; and a set of semiconductor layers formed adjacent to a firstside of the buffer structure, wherein the buffer structure has aneffective lattice constant and a thickness such that an overall stressin the set of semiconductor layers at room temperature is compressiveand is in a range between approximately 0.1 GPa and 2.0 GPa.
 2. Thestructure of claim 1, further comprising a substrate immediatelyadjacent to a second side of the buffer structure opposite the firstside.
 3. The structure of claim 1, wherein the buffer structureincludes: a buffer layer; and an intermediate layer located immediatelyadjacent to the buffer layer and a first semiconductor layer in the setof semiconductor layers, wherein the intermediate layer comprises aplurality of group III nitride semiconductor films.
 4. The structure ofclaim 3, wherein the plurality of group III nitride semiconductor filmsform a superlattice.
 5. The structure of claim 3, wherein a dislocationdensity at a top of the buffer layer is less than or equal toapproximately 1×10⁹ dislocation cores per square centimeter.
 6. Thestructure of claim 1, wherein the set of semiconductor layers includes:an n-type layer located immediately adjacent to the intermediate layer;an active region located on a side of the n-type layer opposite theintermediate layer; and a p-type layer located on a side of the activeregion opposite the n-type layer.
 7. The structure of claim 6, whereinthe active region is configured to emit ultraviolet radiation and has athreading dislocation density in a range of 1×10³ to 5×10⁹ threadingdislocations per square centimeter.
 8. A method of fabricating asemiconductor structure, the method including: selecting a set of growthparameters for growing a buffer structure, wherein the set of growthparameters are configured to achieve a target effective lattice constanta for the buffer structure; growing the buffer structure using theselected set of growth parameters; and growing a set of semiconductorlayers on the buffer structure, wherein the target effective latticeconstant a causes an overall stress in the set of semiconductor layersat room temperature to be compressive and in a range betweenapproximately 0.1 GPa and approximately 2.0 GPa.
 9. The method of claim8, wherein the growing the buffer structure includes adjusting the setof growth parameters to decrease local tensile stresses present duringgrowth and to limit compressive stresses to approximately 1.0 GPa orless during growth.
 10. The method of claim 8, wherein the growing thebuffer structure includes growing a buffer layer directly on a substrateusing a multi-stage process, wherein the multi-stage process includes:growing a plurality of nucleation islands on the substrate; andcoalescing the plurality of nucleation islands into a single layer usinga high growth temperature.
 11. The method of claim 10, wherein thegrowing the plurality of nucleation islands uses a set of island growthconditions selected to grow nucleation islands having a target size anda target density, and wherein the set of island growth conditionsincludes: a duration in a range of approximately one minute toapproximately twenty minutes and a temperature in a range ofapproximately 600° C. to approximately 1300° C.
 12. The method of claim8, wherein the growing the buffer structure includes: growing a bufferlayer; and growing an intermediate layer directly on the buffer layer,wherein the intermediate layer includes a plurality of sub-layers havingalternating tensile and compressive stresses, wherein the stresses areadjusted by varying a V/III ratio used during the growth of theplurality of sub-layers.
 13. The method of claim 12, wherein the growingthe buffer structure further includes: measuring in-situ curvature of anexisting heterostructure after the growing the buffer layer; anddetermining at least one attribute of a material for the intermediatelayer using the in-situ curvature, wherein the growing the intermediatelayer uses a set of growth conditions selected based on the at least oneattribute.
 14. A method of fabricating a semiconductor device, themethod including: fabricating a semiconductor heterostructure for thesemiconductor device, the fabricating including: growing a buffer layerdirectly on a substrate using a multi-stage process, wherein themulti-stage process includes: growing a plurality of nucleation islandsformed of a group III nitride material on the substrate using a V/IIIratio configured to form relatively small islands and a growth durationselected to increase a density of the plurality of nucleation islands,wherein the V/III ratio is in a range between approximately 100 toapproximately 50000, and wherein the duration is in a range ofapproximately one minute to approximately twenty minutes; inducingvertical growth of the plurality of nucleation islands using anincreased growth temperature; and coalescing the plurality of nucleationislands into a single layer using a high growth temperature, wherein thesingle layer is grown to a thickness in a range of approximately 100Angstroms to approximately 100 microns; and growing a set of group IIInitride semiconductor layers on the buffer layer, wherein an overallstress in the set of group III nitride semiconductor layers at roomtemperature is compressive and in a range between approximately 0.1 GPaand approximately 2.0 GPa.
 15. The method of claim 14, the fabricatingthe semiconductor heterostructure further including, prior to thegrowing the set of group III nitride layers, growing a group III nitrideintermediate layer directly on the buffer layer, wherein theintermediate layer is configured to mitigate compression in the set ofgroup III nitride layers.
 16. The method of claim 15, wherein theintermediate layer includes a superlattice including a plurality ofsub-layers having alternating tensile and compressive stresses.
 17. Themethod of claim 15, the fabricating the semiconductor heterostructurefurther, prior to the growing the group III nitride intermediate layer:measuring in-situ curvature of an existing heterostructure after thegrowing the buffer layer; and determining at least one attribute of amaterial for the intermediate layer using the in-situ curvature, whereinthe growing the intermediate layer uses a set of growth conditionsselected based on the at least one attribute.
 18. The method of claim17, wherein the intermediate layer includes a plurality of sub-layers,and wherein the at least one attribute includes an aluminum molarfraction of a first sub-layer located directly on the buffer layer. 19.The method of claim 17, wherein the at least one attribute includes anaverage aluminum molar fraction for the intermediate layer.
 20. Themethod of claim 14, wherein the device is an optoelectronic device.